Integrated wire harness batch production using augmented reality

ABSTRACT

Virtually-integrated wire harness design and automated production systems and methods that achieve completely integrated data management by automatically producing scripts to dynamically propagate production commands and data to various subsystems for handling assembling necessary circuits and wire harness layout boards to produce corresponding batches of wire harnesses while script-based methods control configuring, testing, and using wire harness layout boards, and assembling, testing, reworking, and delivering wire harnesses. Augmented reality is used to assist in the assembly of layout boards and wire harnesses.

CLAIM OF PRIORITY TO PRIOR APPLICATION

This application claims the benefit of prior filed U.S. ProvisionalApplication Ser. No. 62/721,361, filed Aug. 22, 2018. The entiredisclosure, including the claims and drawings, of U.S. ProvisionalApplication Ser. No. 62/721,361 is hereby incorporated by reference intothe present disclosure as if set forth in its entirety.

FIELD OF THE INVENTION

The present invention relates to manufacturing of wire harnesses usingaugmented reality. More particularly, the present invention relates tosystems and methods for complete data management integration inreadily-changeable computer-controlled batch production of wireharnesses, from design and raw wires and terminals to final assembly andquality control.

BACKGROUND

Wire harness assembly has long been a labor intensive exercise which hasnot fully benefited from integrated data management methods due tolong-standing mindsets and formidable obstacles. Wire harness assemblypersonnel have selected, measured, cut, crimped, bent, labeled, andfinally placed, connected, and tied tens, and sometimes hundreds, ofindividual wires of varying lengths, gauges, and types to form acompleted wire harness. If even a single wire in the harness is flawed,the harness may have to be repaired or discarded. Over the years,numerous inventions have attempted to automate some or all of wireharness assembly, with varying degrees of success. Some inventions havefocused on separately preparing wire circuits (i.e., the individual wiresegments with terminals) apart from the wire harness assembly process.In automated wire circuit preparation inventions, machines are used toselect, measure, and crimp roll wire into wire circuits, and then othermeans are used to transport the circuits to an assembly station. Theindividual wire circuits are sometimes stored on reelettes or held byclamps, but these methods have inefficiencies and complexities that havelong needed improvement. Their complex structures, difficulty inadapting to varying wire circuit specifications, expense of acquisition,use, and maintenance have long needed to be improved. For example,winding wire circuits onto reelettes may introduce anomalous springtension and irregular bends. Thus, retrieval systems must either haveadditional complexity to adapt to the varying wire circuit lengths basedon unintended bends and spring tension, or risk failures to retrievesome wire circuits. Winding wire circuits onto reelettes may also resultin plastic deformation of metal wire. This work hardening may causeimmediate wire failure, or may leave a latent defect. The circuit maypass its initial continuity test, but later fail well before its designlife due to the residual stress. Further, the winding, storage, andretrieval systems must consistently secure each wire circuit's ends whenthe circuit lengths can vary due to anomalies introduced by the windingprocess itself.

Other inventions do not wind the wire circuits; rather, they use clampsto hold each outstretched circuit. This requires much more storage spacethan a reelette because of the need to accommodate the full length ofoutstretched wires, isolate each circuit, and provide separationdistance between circuits' clamps. The relatively low storage densityfor the wire circuits can force increased workspace areas, withcorresponding increases in overhead costs. Positioning equipment mustprecisely place the wire circuit for proper clamping, and the clampsmust hold the wire circuit securely. In case of system misalignment orerror, the clamps may damage circuit ends when the circuit is clamped orretrieved. Because the number of clamps is directly proportional to thenumber of circuits to store or transport, the quantity of clamps bringsa corresponding number of mechanical failures. To prevent costlyfailures, operators must incur the costs of monitoring, repairing, andreplacing the clamps. Further, clamps may fail to successfully grip oneor more of the circuit's ends. In such cases, operating machinery maybecome fouled by untethered wire circuits.

When wire circuits are prepared apart from the wire harness assemblyarea, the wire circuits must be moved to the assembly station. The wirecircuits can be transported singly or in batches, but each circuit mustbe uniquely identified so that it can be properly processed. Existingsystems suffer from unnecessary complexities and limitations inmaintaining or transferring the data, as well as in effectivelypresenting the wire circuits in assembly order to a human or machine.

The systems and methods of the present invention overcome many of theproblems and limitations of the prior art. Furthermore, the addition ofaugmented reality displays increases the accuracy, speed, and efficiencyof previous inventions.

BRIEF SUMMARY OF THE INVENTION

The present invention includes systems and methods which providecompletely integrated data management. The methods include producingmachine-readable, standardized scripts that are dynamically propagatedthroughout the entire production system. The present invention alsoautomates many of the steps in configuring, labeling, testing, and usingwire harness layout boards, and in assembling, testing, reworking, andfinishing wire harness assemblies. Aspects of the present invention usepneumatic means to load individual wire circuits into a storage andtransport system, such as a batch cart, for later assembly into one ormore wire harnesses. The batch cart has an array of individual tubesthat are pneumatically loaded with individual wire circuits, one or morecircuits to a tube. The cart contains a memory device that storesidentifying information for each wire circuit including its position inthe tube array. The tubes may vary in diameter or length, but each tubeis of sufficient length to accommodate the wire circuit, or circuits,with which it is loaded. The batch cart supports wire circuits ofvarying types, lengths, and end connectors without the limitations andcomplexities required for coiling the circuits or for individuallyclamping each circuit's ends. The batch cart provides a high storagedensity for the wire circuits and minimizes the materials and spaceneeded to store and transport the circuits. Further, a series of batchcarts can receive wire circuits from an entire production shift andconveniently store the circuits for subsequent assembly.

When the wire harnesses are to be assembled, the batch cart istransported to the assembly area. A pneumatic means automaticallyretrieves each circuit from the indexed tube array and presents it to ahuman or robotic assembler in the order it is to be installed into thewire harness assembly. The assembly area includes a double bufferassembly that greatly reduces the wait time for the assembly personnelfor each circuit element.

A preferred embodiment uses augmented reality glasses to superimposeinformation over real-life programmable modules into the field of viewof the user. Augmented reality glasses may be used to provide visualcues for installation of tool posts (smart jigs) and turning posts insmart boards (programmable modules). In an alternative embodiment,augmented reality glasses can display information and visual cues in aspecific location, such as the top right corner of one lens. In thisalternative, the user is able to look at the real-life assembly and lookto the corner of the lens for guidance. This embodiment differs becausethe information is displayed on the glasses but is not “superimposed”directly over the real-life assembly. Further, the augmented realityglasses are capable of displaying images that provide visual directionto the personnel carrying out the wire harness assembly to direct themto place a given circuit element in a given position and to connect itto the specific bundles and/or connector in place on the physicalharness assembly table.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a view of a wire harness assembly table and a view of a userlooking through an augmented reality display of a particular wireharness assembly in process.

FIG. 2A is a view of two programmable modules or smart boards isolatedfrom the rest of wire harness assembly as seen through augmented realityglasses on an augmented reality display.

FIG. 2B is a view of an augmented reality display with superimposedprompts for instructing the user to install tool posts (smart jigs) andthe corresponding wire harness connectors.

FIG. 2C is a view of an augmented reality display with superimposedprompts for instructing the user to install turning posts and toolposts.

FIG. 3A is a view of augmented reality display as seen through augmentedreality glasses.

FIG. 3B is a view of the illuminated portion of a tool post forproviding guidance to a user for placing a wire harness connector.

FIG. 3C is a view of the illumination of the location where the firstend of a wire should be placed.

FIG. 4 is a view of the augmented reality display with a superimposedindication of successful verification and testing of a circuit element.

FIG. 5 is a view of the augmented reality display with a superimposedindication of failure of verification and testing of a circuit element.

FIG. 6 is an overhead view of a side of a tool post disconnected from anassembly.

FIG. 7 is a view of use of the augmented reality display in a fieldinstallation.

FIG. 8A is a partially schematic perspective view of the circuitmanufacturing sub-system (C&C centers) of the present invention.

FIG. 8B is a partial schematic perspective view of the wire harnessassembly sub-system (assembly table) of the present invention.

FIG. 8C is a perspective view of a computer-controlled X-Y indexingplatform 24 for moving each of three storage buffers to direct eachindividual circuit from the crimp center into a unique correspondingtube location in the buffers.

FIG. 9 is a schematic block diagram of the circuit manufacturing andwire harness assembly sub-systems of the present invention.

FIG. 10A is a detailed perspective view of a typical block tool(connector jig) for use on the assembly table of the present invention.

FIGS. 10B & 10C are detailed partial cross-sectional views of alternateembodiments of the block tool (connector jig) for use on the assemblytable of the present invention.

FIG. 11 is a mixed view hardware/software method flowchart of theoverall system and method of the present invention.

FIGS. 12A-12C are flowcharts of production process steps for circuitmanufacturing, circuit indexing and storage, and guided wire harnessassembly.

FIG. 13A is a partially schematic perspective view of an alternativeembodiment of the circuit manufacturing sub-system (C&C centers) of thepresent invention.

FIG. 13B is a partial schematic perspective view of an alternativeembodiment of the wire harness assembly sub-system (assembly table) ofthe present invention.

FIG. 13C is a detailed side plan view of one of the circuit indexingsub-systems of the alternative embodiment shown in FIGS. 12A and 13B.

FIG. 14 is a partial schematic perspective view of an improvement to thewire harness assembly sub-system (assembly table) as depicted in 8B.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

As indicated above, it is an objective of the present invention toprovide for an extremely flexible manufacturing and tooling system forthe design and production of wire harnesses. The system is designed toallow the same set of tooling structures to be utilized in conjunctionwith a wide variety of wire harness designs and configurations, and atthe same time to maintain a high level of quality control and a highlyefficient manufacturing process. The systems and methods described allowfor the rapid re-tooling of the system to accommodate small or largemanufacturing runs and rapid change-over to the production of a new wireharness design. The systems and methods further facilitate the immediatetesting and verification of the manufactured wire harnesses as well asthe tracking and training of personnel involved in the productionprocess. The following drawing figures provide an overview of thehardware and software systems utilized to carry out the methods of thepresent invention.

The construction of a harness generally comprises the collection,bundling, and association of a large number of circuit elements (wireswith terminal ends) that are collected and assembled into various typesof standard and custom connectors that are positioned on the wireharness table according to a pre-determined layout and configuration.Various components positioned on the wire harness table facilitate theplacement, positioning, bundling, and insertion of the circuit elementsinto the various connectors. As indicated above, existing wire harnessassembly systems typically rely upon the complete manual construction ofa wire harness on an assembly table after which the completed harness isremoved from the table and tested in a separate location, wire by wire,or connector by connector. The present invention improves the efficiencyof the manufacturing process by carrying out testing and verification ofthe wire harness immediately upon placement and connection of eachcircuit element within the wire harness structure.

The system of the present invention further provides prompts,directions, and other instructions to the assembly personnelconstructing the wire harness by way of a number of visual and auralprompts and confirmations. The aural and visual prompts in the presentinvention are provided using a number of different elements in theaugmented reality display 500 of a wire harness assembly sub-system.

As shown in FIG. 1, one of the embodiments of the present inventionincludes an augmented reality display 500 (bottom right corner) of awire harness assembly sub-system. Shown above the augmented realitydisplay 500 is the physical wire harness assembly 50. The display 500 isviewed by a user through augmented reality glasses 560, preferably usingMicrosoft HoloLens augmented reality software. In this embodiment, auser wears augmented reality glasses 560 which superimpose informationover real-life programmable modules (“smart boards”) 54 a, 54 b into thefield of view of the user. The terms “smart board” and “programmablemodule” are used herein interchangeably. The smart boards 54 a, 54 b maywirelessly transmit information via wireless connection 100 that is thendisplayed on augmented reality glasses 560. Such information includesdirections and visual cues for assembly of the wire harness. Theaugmented reality glasses 560 are capable of displaying images thatprovide visual direction to the personnel carrying out the wire harnessassembly to direct the personnel to place a given circuit element in agiven position and to connect it to the specific bundles and/orconnectors in place on programmable modules 54 a, 54 b on the physicalharness assembly table 52. The display 500 of both the real-life viewand other information superimposed is defined here as the AugmentedReality User Interface (“ARUI”).

In an alternative embodiment, augmented reality glasses 560 can displayinformation and visual cues in a specific location, such as the topright corner of one lens. In this alternative, the user is able to lookat the real-life assembly and look to the corner of the lens forguidance. This embodiment differs because the information is displayedon the glasses but is not “superimposed” directly over the real-lifeassembly.

Customization of the wire harness according to specific needs related tospecific connectors and terminal ends, such as the placement ofultrasonic soldering to non-typical connector assemblies, typically willtake place off of the assembly table 52. Other embodiments may employmechanisms placed on tooling configuration system 60 (as shown in FIGS.7B, 13B, and 14) so as to be made accessible to any portion of theassembly table programmable modules 54 a & 54 b. Tooling configurationsystem 60 is preferably positioned in an overhead track-mounted gantryas illustrated. The process of assembling a wire harness 64 inproduction through to completion is partially automated according to theprompting and instruction systems described above, but is ultimatelywithin the manual control of the assembly personnel who initiate andterminate the automated system by activating assembly table start/stopcontrol 68.

Turning to FIG. 2A, there is shown a view of programmable module 54 aand programmable module 54 b as would be seen on the augmented realitydisplay 500. The display 500 illustrates that the programmable modules54 a and 54 b are blank while the wire harness assembly 50 is turned offor prior to the beginning of the process of creating a wire harnessassembly. In this view on the augmented reality display 500, theprogrammable modules 54 a and 54 b are shown in their entirety. Whenwire harness assembly begins, the augmented reality display 500 maysuperimpose instructive features onto the view of programmable modules54 a, 54 b. In other embodiments, augmented reality display 500 zooms into a smaller area of the programmable modules 54 a and 54 b,particularly in the area where placement of the wire harness assemblycomponents is to take place, the zoomed view preferably changing todifferent physical locations on programmable modules 54 a, 54 b based onthe placement requirements of additional wire harness assemblycomponents.

Turning to FIG. 2B, there is shown augmented reality display 500 withprompts for instructing the user to install tool posts (smart jigs) 62and the corresponding wire harness connectors. The dashed rectangle 619represents the location on the assembly table for placing a tool post 62(shown in FIG. 2C). Each different type of wire harness connector (intowhich a bundle of completed circuit elements may be positioned) willhave a specific tool post 62 that interfaces between the connector andthe assembly table programmable module 54 a. On the bottom of augmentedreality display 500, there is shown a text box 622 that is adapted toprovide written instructions and feedback for correct placement andorientation of tool post 62. FIG. 2B shows the proper location 619 offirst tool post 62 and subsequent tool posts will be placed in a similarmanner. Once a tool post 62 is correctly placed, the user then followsinstruction for placement of additional tool posts 62. Similarly,augmented reality display 500 will show the appropriate locations forplacement of additional tool posts.

Turning to FIG. 2C, there is shown augmented reality display 500 withprompts for instructing the user to install turning posts 66. The dashedcircle 659 represents the location on the assembly table for placingturning post 66. In addition to tool posts 62 variably positioned onassembly table programmable modules 54 a & 54 b (as shown in FIG. 1),harness assembly turning posts 66 may likewise be positioned tofacilitate the placement and positioning of the circuit elements (wireswith terminal ends). On the bottom of augmented reality display 500,there is shown a text box 622 with instructions and feedback for correctplacement and orientation of tool post 62. FIG. 2C shows the properlocation 659 of one turning post 66 and subsequent turning posts will beplaced in a similar manner.

The use of augmented reality glasses 560 allows a user to continuelooking down at the physical wire harness assembly 52 while receivingvisual prompts displayed on the glasses 560. The augmented realitydisplay 500 is an improvement because users do not have to continuouslylook up at a separate display while assembling. This augmented realityprocess is more thoroughly explained in the following paragraphsdescribing the wire harness assembly.

Turning to FIG. 3A, there is shown augmented reality display 500 as seenthrough augmented reality glasses 560. The user views display 500 whilelooking down at wire harness assembly table 52. It is important to notethat virtual prompts displayed in display 500 are limited to theimmediate area around the particular tool post being utilized at a giventime. In this case, for active tool post 62 a, the text box 622, wireharness path 610, and lighting directing the placement of harnessconnector 92 are all virtually displayed to the user being superimposedon the actual view of the physical programmable modules 54 a, 54 b. Theadditional components visible in augmented reality display 500 are thereal-life components, such as programmable modules 54 a, 54 b and allthe tool posts 62. The text box 622 gives instructions to the user toretrieve a particular wire harness connector 92 from a bin array (notshown) and to place the connector into tool post 62 a. Text box 622preferably appears directly above the placement location. Various toolposts 62 are positioned on the assembly table programmable modules 54 a& 54 b and provide lighted indicators associated with the variousconnector ports directing the assembly personnel to insert a circuitelement terminal end into a particular port on a particular harnessconnector 92. The system selectively illuminates individual wire portsin the tool posts 62 when the next step in the physical assembly 50requires connection at the illuminated port. Such port illuminationserves to ease the assembly process by designating the next succeedingstep in the assembly, as appropriate. Turning posts 66 are alsoilluminated with at least four bright LEDs to assist in illuminatingpath 610. If the wire makes a right angle at turning post 66, only threeLEDs would illuminate corresponding to the two directions along whichthe wire should be routed. In this manner, for example, the automatedsystem of the present invention may provide a multi-faceted visualprompt to direct the placement of a particular circuit element along aphysical path 610 associated with the physical assembly 50. Once thecircuit has been positioned along the appropriate wire harness path 610,the individual attachment of the terminal ends of the circuit to theappropriate connectors may be directed by way of illuminated tool posts62 which hold the individual connector structures. The user may theninsert the appropriate terminal ends of the circuit element 64 (shownplaced in position in FIG. 4) into the appropriate connector port asprompted by the illumination.

With reference to FIG. 3B, there is shown the illuminated portion oftool post 62 for providing guidance to a user for placing wire harnessconnector 92 (not shown). Tool post 62 is depicted and described ingreater detail in FIG. 6 and ensuing paragraphs. Each tool post 62 has atranslucent panel on its side that glows, and has at least fourtranslucent dots 300 on top that glow brightly. The translucent dots 300indicate to the user to “place the harness connector here.” A pushbuttonswitch 621 allows the user to respond affirmatively to prompts and can“lock” harness connections in place.

With reference to FIG. 3C, there is shown the illumination of thelocation 311 where the first end of a wire should be placed. Thetranslucent dots 300 and location 311 are both illuminated. Within thecavity 310 of the connector, the hollow cavity probe (not shown)transmits light from a very high intensity LED. The light shines all theway through the cavity 310 of the connector and serves to illuminatelocation 311 which will receive a circuit element 64 (as shown in FIG.4).

Turning to FIG. 4, there is shown the augmented reality display 500resulting from successful verification and testing of a circuit element64 a. Circuit element 64 a is connected to harness connector 92 and toolpost 62 a and wraps around turning posts 66. Another end of circuitelement 64 a is connected to tool post 62 b. Once these connections aremade for circuit element 64 a, the single board computer 720 (shown inFIG. 6) inside tool posts 62 a, 62 b interfaces with programmablemodules (smart boards) 54 a, 54 b and verifies that the properconnections were made. Next, the circuit element 64 a is tested toensure that it is functioning properly and there are no faults in thewiring. A single board computer 720 in tool post 62 b transmitsinformation regarding verification and testing to augmented realityglasses 560. In this case, the circuit element 64 a was placed correctlyand tested successfully. Therefore, there is a green indicator light 650virtually displayed above tool post 62 b indicating a successfulconnection.

Turning to FIG. 5, there is shown the augmented reality display 500resulting from failure of verification and testing of a circuit element64 b. Connecting circuit element 64 b to tool post 62 c is the next stepin the wire harness assembly 50. Once again, a single board computer 720within tool post 62 c transmits information regarding verification andtesting to augmented reality glasses 560. In this case, the circuitelement 64 b was connected correctly but tested faulty. There is a redindicator light 651 virtually displayed above tool post 62 c indicatingfailure. There is also a text box 622 display that provides instructionsthat informs the user that the circuit element 64 b was placed correctlybut there was a testing failure. Similarly, a red indicator light 651will be virtually displayed if circuit element 64 b was not connectedcorrectly. The user can then disconnect circuit element 64 b and connectit to whichever tool post 62 is proper.

To enable taping and loom assembly on the wire harness, correspondinginstructions are displayed on the augmented reality glasses 560 at theappropriate step in assembly, and the user manually indicates completionof the taping or loom application step rather than an automated sensing.In addition, taping and looming steps are facilitated by theincorporation of stand-off blocks (illustrated schematically on eachtool post 62 in FIG. 8B) which provide a separation of at least ahalf-inch (preferably at least 1.5 inches) between the plane of thesmart boards 54 a and 54 b and the point on the block tool 62 wherecircuit terminals connect to the block tool 62. Such minimum separationhelps to allow enough space for assembly personnel to fit their fingersbeneath the wire assembly to enable taping and looming.

Another possible feature of the augmented reality glasses is a cameradevice and a transmitter. The camera can view the wire harness assembly50 and capture images during the assembly process. The transmitter cansend images to the computer system 40 so that it can verify theconnections of circuit elements 64. In this manner, the camera can actas a redundant verification to the primary verification executed onharness assembly table 52 and provided by tool posts 62.

Turning to FIG. 6, there is shown an overhead view of a side of a toolpost 62 disconnected from an assembly. A support post (aluminum shaft)700 protrudes from tool post 62 through the top surface of a smart board(such as programmable module 54 a). Tool post 62 preferably incorporatesa single chip set 730 with orthogonal accelerometers that enables toolpost 62 to report its orientation. In alternate embodiments, in order todetermine the placement of tool post 62, and as a backup for determiningthe orientation of tool post 62, the bottom end of support post 700 canbe cut in a specific way in order to reflect light in a preferentialdirection from an infrared (“IR”) emitter in the center of each smartboard orientation detection array. This enables IR optical sensorsinside the smart board to determine which way the tool is pointing.Aluminum is preferably used as the material for support post 700 becauseof its IR reflectivity. Steel and stainless steel absorb much more IRand would not be able to function as a support post 700. A clamp (notshown) can be used to affix tool post 62 to the top surface of a smartboard. Although not shown, other methods of securing the position oftool post 62 may be used. For instance, a metal plate may be positionedbelow the surface of the programmable modules 54 a, 54 b. At or near thebottom surface of tool post 62, there may be positioned a rare earthmagnet. Upon placement of tool post 62, the magnet contacts the metalplate, thereby securing tool post 62 in place.

By industry standards, connector blocks are designed to receive aparticular wire harness connector. Here, the connector block 710 ismodified with hollow contact test probes which can transmit light intoeach connector cavity. The connector block 710 also has a locking devicein order to retain wire harness connectors 92, and other sensors tocheck the status of various locks and other accessories that may beinstalled into the harness connector 92.

Another major feature of tool post 62 is the single board computer 720(inside tool post 62) that interfaces with a smart board and acts as aninterpreter between the various connector test contacts and the systemnetwork. A cable 725 connects the single board computer 720 to the smartboard. The single board computer 720 also monitors connector accessoryand lock switches and reports their statuses to the network.Additionally, the single board computer 720 also routes test signalsdelivered via the network to the appropriate connector cavity, andevaluates electrical characteristics at each contact to determinewhether or not they might be connected via the harness assembly to othertool posts and connectors distributed over the smart board 54. Thisprocess enables the system to perform continuity, tensor impedance, andfrequency response tests between cavities of multiple connectorsinstalled at various locations across the smart board 54 during wireharness assembly. The network of multiple single board computers 720 isable to test for errors at all points in a wire harness assembly 50 andeffectively take “snapshots” of the whole smart board 54. Electricalshorts can be specifically identified and illuminated so that the usercan make any necessary adjustments.

Additionally, tool post 62 has a high intensity LED board (not shown)that accepts signals from the single board computer 720 and illuminatesvarious portions of the tool post 62, along with the cavity fiberoptics. An enclosure 750 mounts the support post 700, clamp, computercircuit boards 720, and connector block 710 together. At least onepushbutton switch 621 (not shown here) is mounted to the enclosure 750,which allows the user to respond affirmatively to prompts.

In alternative or supplemental embodiments, the system operates inanother mode where instead of or in addition to the wire harnessassembly on the board, there are one or more wire harness terminationsor connections that are completed in the field, particularly at or nearthe time of installation of the wire harness assembly in the equipmentfor which the wire harness assembly is made. For example, as illustratedin FIG. 7, there is shown an open panel 900 on an aircraft wherein awire harness assembly is to be installed. Using augmented realityglasses 560, an installer is able to view the relevant interior portionof the aircraft, and augmented reality display 500 superimposes theimages of the wire harness assembly components and the appropriateconnections are also highlighted in the augmented reality display 500.Furthermore, as with the embodiment described in FIG. 3A, a text box 622is shown on augmented reality display 500 to provide written instructionto assist the installer in making the appropriate connections. Usingaugmented reality glasses 560 serves to reduce or prevent faults andmisconnections in the field when installing a completed wire harnessassembly.

Reference is now made to FIGS. 8A & 8B for an overview of the varioussub-systems that collectively are engaged in the overall process for theproduction of wire harnesses according to the present invention. FIG. 8Ais a partial schematic view of the circuit manufacturing sub-system (C&Ccenters) 12 of the present invention involving the manufacture of theindividual wire/terminal circuits 20 that collectively go together tomake up a wire harness. In general, reference herein to a circuit 20refers to the manufactured combination of a length or lengths of wireprovided with (where applicable) one or more terminal ends (typicallyone length of wire with terminals at each end), that are collectivelygathered into and make up the components within a wire harness. Theterminal ends are variable in configuration and may simply involve awire end stripped and tinned (with solder) for purposes of laterattachment to a terminal block or circuit board. In most instances,however, a circuit comprises a length of wire that terminates at eachend with a crimp-on metal terminal, typically of a pin or spade type.The crimp-on terminals may be either male or female. These metalterminals are most frequently designed to be collectively integratedinto what will herein generally be referred to as a connector, whichforms the end of a bundle of wires within a wire harness.

FIG. 8A shows the circuit manufacturing sub-system 10 as incorporatingautomated C&C center 12. This C&C center is in turn associated withindexed circuit storage system (cart/magazine) 36. These basicsub-systems collectively serve to manufacture the circuit elementsutilized in the production of the wire harness and store them,preferably in a manner that can be readily and robotically retrieved forfinal assembly. Automated C&C center 12 is preferably a combination ofsubsystems assembled from a number of different commercially availableautomated wire cutting systems and automated stripping and crimpingmachines as well as wire labeling systems. Numerous manufacturers areknown with various tools (for example, the Schunk-Minic, Schleuniger andCurti lines) that can be combined to achieve the described functionalityof C&C system 12. The C&C center 12 preferably includes an array of wiresupply reels (auto feed) 14 and an associated array of wire terminalsupply cartridges (rolled bands of pre-cut sheet metal terminals withtabs, often referred to as “bandolier” rolls) 16.

Although some of the different supply reels 14 have different wiregauges, insulation and ratings than other reels 14, as is input andknown by the programming of C&C system 12 (or that of the overall system10), the wire insulation on all the wire supply reels 14 of C&C center12 is preferably blank and of a white (or, alternatively, an assortmentof solid pale colors) so that a wire label print can be applied to allthe circuits 20 by C&C center 12 as the circuits are being cut, strippedand crimped. Tag labels as are known in the industry may also be appliedby C&C center 12, to the extent required in the circuit specifications.Although not illustrated, those of skill in the art will understand howC&C center 12 is adapted to perform such label printing and applicationbefore the circuits 20 are stored in buffer 36.

Automated C&C center 12 will typically have at least one means forprogramming the device. The device may be programmed by operatorcommands entered into C&C center programming terminal 18. In anotherembodiment, automated C&C center 12 may be programmed from a remote datainput terminal device 40. In yet another embodiment, automated C&Ccenter 12 may be programmed by importing files from CAD software 104(shown in FIG. 11).

Automated C&C center 12 produces a completed wire/terminal circuit 20 ofa length, gauge, and terminal type, as specified by the programmingprovided to automated C&C center 12. Such programming is versatile andcan direct automated C&C center 12 to produce a large number of a singletype of circuit 20 or a long list of entirely distinct circuits thattogether might be eventually bundled to form a wire harness. In thepresent invention, a very efficient operation of automated C&C center 12would be to produce a long list of individual circuits required toconstruct one particular type of wire harness. The C&C center mayproduce a number of circuit sets that are indexed and stored (asdescribed in more detail below) and then later utilized to produce anumber of the same type of wire harness.

Automated C&C center 12 provides a completed wire/terminal circuit 20which is delivered into an indexed circuit storage system 36 by way ofan associated pneumatic conduit 22 and a circuit indexing sub-system 24(shown in FIG. 13A). The indexed circuit storage system 36 is preferablyembodied as a magazine, also referred to as a “buffer,” that includesnumerous single-circuit containers 39 into which the production systemdeposits individual circuits 20, storing a record of which circuits 20or types of circuit 20 are stored in which containers 39 so that thosecircuits 20 can later be retrieved from the buffer 36 when needed tomake the final wire harness assemblies. Although some of such containers39 may be sized differently than others according to the productionneeds, in the most preferred embodiment, such containers 39 are embodiedas an array of identical tubes 39. Each such identical tube 39 is longenough to contain the longest wire that would be required in the wireharness batch being assembled (ten feet is typically sufficient) and issized roughly ⅝ or 9/16 of an inch in inside diameter so that thelargest of typical circuit terminals fit loosely within the tubes 39 butare still within fairly close tolerances in order to optimize space aswell as the efficiency of the pneumatic system used to move the circuits20 into and out of each tube 39. The tubes (or at least their interiorsurfaces) are preferably made of a low-friction material such as PVC orbetter in order to minimize the possibility of a circuit 20 hanging upor getting stuck in a tube 39 when the pneumatic conveyance system isattempting to move it.

Buffer 36, hence, is configured with a large array of linear tubes 39,each of which preferably only holds a single circuit 20, configured in afixed, parallel arrangement. (It is envisioned that alternative, albeitless beneficial, embodiments may hold one or more completedwire/terminal circuits 20 in individual containers 39 while stillappreciating some of the benefits of certain aspects of the invention.)This array of storage tubes 39 operates in conjunction with circuitindexing sub-system 24 such that every tube 39 within the array 38 ofthe cart/magazine is identified and indexed to contain a known type ofcircuit element 20. In this manner, indexed circuit storage system 36may be loaded with a full circuit element set appropriate for themanufacture of one or more particular batch(es) of wire harnesses. Wireharnesses may of course come in a variety of configurations having lessthan ten circuit elements to hundreds of circuit elements. Indexedcircuit storage system 36 is designed to accommodate simple or complexwire harness circuit sets.

The combination of a circuit indexing sub-system 24 (shown in FIG. 13A)and pneumatic conduit 22 deliver completed wire/terminal circuits 20from the automated C&C center 12 into a properly indexed storage tube 39within indexed circuit storage system 36. In one embodiment, a circuitis transported from the automated C&C center into storage system 36 bypneumatic tube 22. Circuit 20 enters tube 22 at 22 a where opticalsensors 77 and 78 detect its entry into tube 22. Device 83 is a meansfor supplying pneumatic pressure into tube 22 to transport circuit 20through tube 22 from entry at 22 a to exit at 22 b. As the circuit exitstube 22, optical sensors 79 and 80 detect its passage. In oneembodiment, circuit 20 is inserted into a particular tube, for exampletube 39 a, in storage system 36 by moving storage system 36 such thatthe longitudinal axis of tube 39 a is generally aligned with thelongitudinal axis of pneumatic tube 22 and the receiving end of storagetube 39 a is close enough to discharge end 22 b to reliably receive thecircuit. Arrows 811 a, 811 b, and 811 c show how storage system 36 ismoved in an X-Y coordinate system to align a receiving tube with thedischarge end 22 b of tube 22. Movements of storage system 36 arecontrolled by a computer system that maintains the index system and isable to move storage system 36 across the X-Y coordinate system to alignany individual tube to receive a circuit. The vertical surface plane ofstorage system 36 (formed by the tube ends including tube 39 a and 39 b)is maintained in a vertical orientation which results in the surfaceplane being generally normal to the longitudinal axis of pneumatic tube22. To insert a circuit into tube 39 b, storage system 36 is movedvertically, but not horizontally, so that the receiving end of tube 39 bis aligned with discharge end 22 b and is ready to receive a circuit. Asmentioned above, the entire indexing system may be programmed and may becontrolled by way of a computer system 40. In some embodiments, acomputer system 40 may be located on storage system 36. In a preferredembodiment, computer system 40 is a computer server system. Regardlessof where computer system 40 is located or its particular configuration,each completed wire/terminal circuit 20 from the respective C&C center12 may be directed into a known and indexed storage tube 39 where it maybe held until such time as the manufacturing of that particular wireharness assembly is carried out.

In some embodiments, the indexes and circuit descriptions are stored ina memory device downloaded to and physically located in or on storagesystem 36 so that the cart can be temporarily stationed in a holdingarea and its data can be retrieved whenever it is ultimately wheeledinto position for wire harness assembly (as depicted in FIG. 8B). In apreferred embodiment, however, the data pertaining to a particularbuffer 36 loaded with circuits 20, including the descriptive informationfor each circuit 20 and the location of its tube 39 within storagesystem 36 is stored in computer server system 40. Each storage system 36entity is marked with a bar code that uniquely identifies the storagesystem. With the bar code identifier, the index system, and the circuitdescriptions, the production system identifies each circuit regardlessof where it is stored.

In a first preferred embodiment of the present invention, each of thestorage tubes 39 associated with indexed circuit storage system 36 maybe designed to retain a single circuit element 20 for later deliveryduring the assembly of the wire harness. Alternate embodiments of thepresent invention anticipate the utilization of storage tubes 39 capableof retaining a number of like circuit elements 20 for later use anddelivering such circuit elements 20 one at a time in a repetitivemanner. Therefore, the index circuit storage system(cart/magazine/buffer) 36 may be configured to receive, store, anddeliver a full circuit element set appropriate for the manufacture of asingle wire harness or, in an alternate embodiment, the same cart 36 maybe configured to receive, store, and deliver ten or more sets of circuitelements 20 by repeatedly drawing out a full set for the manufacture ofa wire harness followed by second and subsequent full sets all from thesame storage cart 36.

Reference is now made to FIG. 8B for a detailed description of what isessentially the second half of the wire harness production process. Thesub-systems described in FIG. 8A above, produce the building blockcomponents that are to be assembled into the final wire harness product.These building block components are, as described above, circuitelements 20 comprising lengths of wire with terminal ends attached.These completed wire/terminal circuits are stored, either for a periodof time or for as long as it takes to move the storage cart 36 to thewire harness assembly sub-system 50. FIG. 8B shows the same indexedcircuit storage system 36 as shown in FIG. 8A, this time providingstored circuit sets to the wire harness assembly sub-system for thepurposes of completing the manufacture of the wire harness. In the viewshown in FIG. 8B, indexed circuit storage cart 36 is moved to a positionadjacent the wire harness assembly sub-system 50. In some embodiments,indexed circuit storage system 36 includes, as indicated above, acomputer system 40 that facilitates the automation of the process ofindexing, storing, and delivering the circuit elements 20. In apreferred embodiment, the circuit descriptions and indexes are stored ina computer server system 40. Also shown in FIG. 8B is storage cartoutput port array 42 similar in structure to the storage cart input portarray 38 shown in FIG. 8A. In one embodiment of the present invention,storage cart output port array 42 may comprise the same array of ports39 as storage cart input port array 38, and cart 36 is simply turnedaround for receipt or delivery of the circuit elements. Alternately,these storage cart port arrays 38 and 42 may comprise opposite ends ofthe mobile indexed circuit storage systems (cart/magazine) 36.

As with the input of circuit elements 20 into indexed storage circuitsystem 36, the output or delivery of the circuit elements 20 is carriedout by effectively reversing the indexing process and selectivelywithdrawing the appropriate circuit element 20 from the storage cart 36to be delivered to the wire harness assembly sub-system 50. In at leastone embodiment, computer controlled electric motors position storagesystem 36 so that the tube with the next circuit required in the wireharness is aligned with a pneumatic tube that ejects circuit element 20onto conveyor belts 202 and 204 to deliver the circuit element 20 toassembly sub-system 50. This delivery is again carried out by way ofpneumatic conduit 46 (shown in FIG. 13B) which withdraws a circuitelement 20 from storage system 36 and delivers it to wire harnessassembly sub-system 50 for use in conjunction with the assembly process.

The actual assembly of the wire harness is carried out manually,although this assembly process is directed, prompted, tested, andverified automatically in conjunction with the elements of the system ofthe present invention as described in more detail below. While assemblypersonnel manually receive circuit elements from the circuit indexingsub-system 44 by way of the pneumatic conduit 46 as described above, theprocess of placing the circuit element 20 onto the assembly table 52 andmaking the appropriate connections is automatically guided and confirmedby the systems and methods of the present invention.

The assembly table of the present invention is generally comprised ofassembly table support frame 52 which positions and supports one or moreassembly table programmable modules represented by 54 a & 54 b in FIG.8B. In the preferred embodiment of the present invention, a versatilesystem might incorporate as many as twelve assembly table programmablemodules, with four layout boards per module, that may be usedindividually or collectively depending upon the size and complexity ofthe wire harness being constructed. These table modules areinterconnectable and may be used separately or collectively according tothe requirements of the system and the personnel handling the wireharness assembly.

Reference is now made to FIG. 8C for a more detailed description of apreferred embodiment of the circuit transfer system of the system andmethod of the present invention. FIG. 8C is a perspective view of acomputer-controlled X-Y indexing platform 85 for moving each of threestorage buffers 312 a, 312 b, 312 c to direct each individual circuitelement 20 from the crimp center 12 into a unique corresponding tube 39located in the buffers 312 a-312 c. A such, X-Y indexing platform 85serves as one of the two circuit indexing sub-systems utilized todeliver completed circuit elements into and out from the mobile storagesystem 36 (cart/magazine) of the present invention. It is understoodthat, as discussed above, such an indexing sub-system would preferablybe positioned in conjunction with both the circuit manufacturesub-system (the C&C centers) and the harness assembly sub-system (thesoft-tool assembly tables) and would provide the manner of directingcompleted circuit elements 20 into the mobile indexing storage cart 36as well as providing delivery of the same from the mobile cart 36 to theharness assembly table 52.

Those skilled in the art will recognize that the system may preferablyinclude two such circuit indexing sub-systems, one for delivery of themanufactured circuit elements 20 into the storage cart 36, as shown inFIG. 8A, and one for delivery of the indexed circuit elements 20 fromthe storage cart 36 to the assembly table 52, as partially shown in FIG.8B. Alternately, the storage cart might retain a single array of portsthat serve as both the input and output ports for reception and deliveryof the various circuit elements 20 stored within the mobile cart 36. Inother words, the circuit indexing sub-system 85 shown in FIG. 8C couldalso serve as the circuit indexing sub-system 24 described above forreceiving manufactured circuit elements 20 into the cart 36. It would bea simple matter of connecting and disconnecting the pneumatic hosesassociated with each of the stations discussed above and appropriatelyprogramming the X-Y indexing and sorting system to either direct(pneumatically) a just completed circuit element 20 into the storagecart 36 or to withdraw a previously indexed circuit element 20 from thecart 36.

FIG. 8C shows one embodiment of the present invention and depictsstorage systems 312 a, 312 b, and 312 c that are positioned by circuitindexing system 85. System 85 uses commercially available means such ascomputer controlled electric motors operating lift and side-to-sideconveyor mechanisms to move the storage systems 312 a-312 c. Preferably,electric motor screw jacks at the base of each of the four verticalframe members 99 a-99 d control the coordinated vertical movement offorward and rear support beams 94 a & 94 b in the (vertical) Y axis(arrows 811 a, 811 c), which in turn support the three buffers 312 a,312 b, and 312 c. Simultaneously, coordinated forward and rear chainlink belt drives (not shown but understood by those of skill in the art)within the forward and rear beams 94 a & 94 b preferably controlmovement in the (horizontal) X axis (arrows 811 b, 811 d).

The respective motions are controlled and recorded so that theindividual tube number and location is recorded in a storage system datastructure as previously described. For example, when a circuit element20 is prepared by automated C&C center 12 and ready for transfer into astorage system tube such as 39 a, computer-controlled circuit indexingsystem 85 positions tube 39 a to receive the circuit. If the nextcircuit is to be stored in tube 39 b, circuit indexing system 85 movesthe platform vertically to prepare tube 39 b to receive the next circuitelement 20. Those skilled in the art will be able to appreciate othermeans that could be used to position individual tubes to receive acompleted circuit element 20 from the automated C&C center 12 or totransfer a circuit element 20 to assembly system 50.

In addition, the circuit indexing system 85 preferably and automaticallycreates an offset in the height of the forward and rear beams 99 a and99 b in order to take advantage of gravity in moving circuits relativeto tubes 39, thereby creating a slight tilt in the slope of the buffers312 a-312 c in order to minimize hang-ups in circuit conveyance. Whenused in the preferred embodiment, the buffer tilt (subtly illustrated inFIG. 8A) is at least four degrees when viewed from the side. Idealbuffer tilt angles for a given pneumatic conveyance system can bedetermined by experimenting to find the angle that most closely matchesthe natural trajectory of a typical circuit 20 exiting end 22 b of tube22, and the computer control system is adapted to automaticallyintroduce that determined tilt to favor the direction of conveyance.

Reference is now made to FIG. 9 for an overview of the flow of theproduction process associated with the system and method of the presentinvention. FIG. 9 is a schematic block diagram of the circuitmanufacturing and wire harness assembly sub-systems of the presentinvention. While FIGS. 8A, 8B, & 8C provide a better overview of thestructural hardware requirements of the system, FIG. 9 characterizes theprocedural or process flow operable in conjunction with the sub-systemsin a more concise view. In FIG. 9, automatic C&C center 12 is providedwith wire supply reels 14 and wire supply cartridges 16 as describedabove. The manufacturing process flows from the C&C center to circuitindexing sub-system 24. This sub-system 24 provides automatic preparedwire indexing, sorting, and delivery by way of the combination ofpneumatic ejector tube 22 and the X-Y indexing frame/track for buffer 36(described in detail below).

The indexing, sorting, and delivery system, either 24 or 85, deliversthe prepared circuit elements to indexed circuit storage system(cart/magazine/buffer) 36. Again, as discussed above, this potentiallylarge number of circuit elements 20 produced and stored may representall of the necessary circuit elements for the construction of a singlewire harness or may represent multiple circuit element sets appropriatefor the manufacture of multiple wire harnesses. In any event, thesecircuit elements 20 are delivered to the programmable, automated,prepared wire index storage system (cart/magazine/buffer) 36 that, inthe preferred embodiment, is a mobile cart capable of being moved froman initial location adjacent the C&C center sub-systems 12, 22 to alocation adjacent the assembly table sub-system 50. This movement isrepresented in FIG. 9 by the line connecting the solid outline circuitstorage cart 36 to dashed outline circuit storage cart 36. Essentially,the top part of FIG. 9 represents the C&C center sub-system(s) 12, 22whereas the bottom part of FIG. 9 represents the wire harness assemblysub-system 50.

Once the prepared and indexed circuit elements 20 are stored in indexedcircuit storage system 36, they are moved to the assembly location wherethey are delivered to the wire harness assembly table 52 by way ofcircuit indexing sub-system 44. In a manner essentially the reverse ofthe action associated with circuit indexing sub-system 24 or 85,indexing sub-system 44 provides the automatic, indexed, prepared circuitwire delivery, by way of X-Y extraction (not shown in FIG. 9) to theassembly table components of the system of the present invention.Indexing sub-system 44 is discussed below, but as noted above,essentially the reverse action of circuit index system 24 or 85 may beused to retrieve circuits in order from storage system 36 forpresentation to the assembly person via conveyor belts 202 and 204. Whenthe retrieval system, whether using system 44, system 85, or a variant,delivers a circuit to the assembler, the delivered circuit element ishandled by the assembly personnel and is placed on the assembly table 52by connection to block tools (connector jigs) 62, which in the preferredembodiment are sequentially illuminated (as described below) andelectrically connected for easy identification and for subsequentelectrical testing. Also as mentioned above, programmable assembly tablemodules 54 incorporate programmable electrical connector arrays and LED(fiber optic) indicator arrays for the purpose of facilitating andguiding the wire harness assembly.

Wire harness 64 is therefore assembled by placement of the individualcircuit elements 20 between the connector jigs 62. The method ofprogressing step by step through the process of assembling the circuitelements 20 into the wire harness 64 is assisted by at least one of thefollowing: 1) augmented reality glasses 560 providing augmented realitydisplay 500; or the programmable image projection system or harnessassembly sequence projectors 56 (shown in FIGS. 13b and 14). Once thewire harness 64 has been completely assembled (and tested and bundled),the finished wire harness product 64 is removed from the table 52 and isnow ready for packaging and delivery.

Reference is now made to FIG. 10A for a more detailed description of theelements of the system of the present invention that facilitate theactual connection between a completed circuit element as described aboveand a connector block making up a terminal end of a portion of a wireharness assembly. As discussed above, wire harnesses are generally madeof bundles of wire that are collectively gathered into a variety ofdifferent standard sized connectors which, when installed in theelectronic or electrical devices associated with the wire harness, serveto appropriately connect the various components within the largerelectrical or electronic device. As indicated, these connectors may beconsidered standard in configuration, although just as often there areunique or customized connector structures that must be utilized in agiven wire harness configuration. In any event, it is an object of thepresent invention to provide an adaptor tooling base that allows aparticular wire harness connector to be positioned on and connected tothe programmable assembly table modules described above.

In the preferred embodiment, the assembly table modules 54 areconstructed of large scale arrays of electrical and optical connections.These “breadboard” type platforms provide a programmable array ofelectrical connectors and fiber optic light conduits between a source(electrical or light) into the variously placed block tools positionedon the assembly table programmable modules 54. Every different type ofwire harness connector 92 (into which a bundle of completed circuitelements may be positioned) will have a specific block tool or connectorjig that interfaces between the connector 92 and the assembly tableprogrammable module 54. In the example shown in FIG. 10A, block tool(connector jig) 62 is configured to serve as an adaptor between theassembly table (not shown) and the wire harness connector 92 (typical).The connector interface 90 provides the specific connection between wireharness connector 92 and the standardized configuration of tool base andtable interface 88. In the preferred embodiment, this specific tool baseand table interface 88 provides on one side the appropriate connectionsthrough connector interface 90 to receive and retain the specific typeof connectors shown, in this case wire harness connector 92. Connector92 in the example shown has a connector wire circuit port array 96positioned on a distal face so as to receive a number of individualwire/terminal circuits 48 that have been delivered to the wire harnessassembly table. The assembly personnel take each of the wire/terminalcircuits and insert a terminal end of the same into the appropriateconnector wire circuit port positioned in port array 96.

Initially, block tool 62 is connected to the assembly table programmablemodule 54 by way of an array of block tool connection pins 98. Asindicated above, these connections may comprise both electricalconnections and optical or light connections for the transmission of notonly electrical current (primarily for testing the established wireharness circuitry) but also for prompting of locations for assemblypersonnel placement of the individual wire/terminal circuits 48.

FIGS. 10B &10C show alternate embodiments for the internal structure ofthe block tools (connector jigs) and therefore imply alternateembodiments for the structure of the assembly tables. It is understoodthat the use of visual light prompts to assist with the proper placementof each of the wire/terminal circuits 48 can be achieved either bypositioning lights (such as LEDs) within interface connector 90, asshown in FIG. 10B, which LED lights 89 shine by way of optical waveguides 87 through electrical test probe/light prompt source 86, and thenthrough connector 92 to the appropriate port opening for reception of agiven manufactured circuit 48. Alternately, as shown in FIG. 10C, blocktool 62 may simply connect by way of fiber optic light guides 95 to theappropriate insertion port with a programmed LED illumination fromwithin assembly table programmable module 54. In other words, the lightsources appropriate for prompting the proper insertion of a circuit intothe connector, may originate either in the block tool itself (in whichcase, controller 93 positioned on microcontroller PC board 91 may serveto turn the light sources 89 on or off) or may originate within theassembly table itself, in which case fiber optic wave guides 95 in FIG.10C would be required to carry such prompting light indicators to theappropriate port opening in the connector port array.

As indicated above, it is anticipated that the various standard sizedconnectors would each have a standard block tool or connector jig foruse in connection with the assembly of a particular wire harness. It isanticipated that many such block tools or connector jigs would bepre-built and available for use with as many different types ofconnectors as would be typically constructed within the wire harnessesas assembled. In addition, generic block tools might be created toreceive and retain circuits that are not directed through standard sizedconnector assemblies.

It will be understood by those skilled in the art that the variousfunctions intended to be carried out by the block tools of the presentinvention may be carried out with a large number of connections(electrical and optical) between the block tool and the assembly tablemodule (as shown in FIG. 10C) or may be effectively multiplexed througha small number of digital signal connections between the block tool andthe assembly table (as shown in FIG. 10B). In other words, the blocktool utilized in the present invention may be a simple (“dumb”)connector for relaying the electrical and optical circuits originatingfrom the assembly table module to the connector to facilitate itsassembly and testing, or the block tools themselves may involve “smart”devices capable of receiving a digital signal from the assembly tablemodule and translating that signal into the appropriate testingelectrical currents or the appropriate optical prompts for directing themanufacture and assembly of the wire harness in association with thevarious connectors.

The present invention anticipates a range of structural components thatplace more or less complexity into the structure of block tool 62varying from simple optical and electrical connections to complexdigital devices capable of receiving coded signals from the assemblytable and providing (or not providing) the appropriate or inappropriateoptical prompts and electrical test currents. The advantages of a“smart” block tool include the ability to repair a faulty connection bysimply replacing the block tool being utilized, as well as greatlysimplifying the electrical and optical structures associated with theharness assembly table module configuration. With a smart block tool,communication between the block tool and the assembly table module mayrequire little more than a single pair of electrical wires (or the twopairs shown in FIG. 10B). On the opposite end of the spectrum, a simpleblock tool that is little more than an array of electrical and opticalconductors would require a much more complex array of similar conductorsand connectors between the block tool and the programmable assemblytable modules. In the latter embodiment, the assembly table moduleswould be much more complex with each individual electrical and opticalconnection being carried between the table and the block tools. Whilethis simplifies the construction of the block tool itself (making theblock tools much less subject to error), the structure significantlycomplicates the assembly table configuration and therefore makes it moredifficult to troubleshoot and solve errors and problems in theelectrical and optical connections. Various installations of the systemsand methods of the present invention may dictate a preference for smartblock tools and much simpler construction for the assembly tablemodules, while other environments may dictate the use of “dumb” blocktools and “smart” configurations within the assembly table modulesthemselves.

Reference is now made to FIG. 11 for a broad overview of the entiresystem and associated methods of the present invention. FIG. 11 is amixed view hardware/software method flowchart of the overall system andmethod of the present invention, showing the functional relationshipbetween the various components within the system, the data flow withinthe system, and the time-based sequence of production method stepsinvolved. In general, the elements shown in FIG. 11 may be identifiedaccording to the configuration provided for each component. The hardwaresub-systems of the present invention are presented in bold rectangles(comprising the circuit manufacture sub-system and the harness assemblysub-system, as well as the harness itself). Functional operations areprovided in non-bold rectangular blocks with directional arrowsrepresenting method flow. Oval shaped blocks in FIG. 11 generallyreflect data, either assembled or programmed, utilized to carry out themanufacturing methodology of the present invention.

As indicated above, the fundamental hardware sub-systems of the presentinvention comprise circuit manufacturing sub-system 122 and wire harnessassembly sub-system 134. The final goal of the overall system is theproduction of harnesses 136. The process carried out may generally beconsidered to start with the electronic schematic 102 which is aninitial (generated) schematic of the final wire harness desired to beproduced. A commercially available CAD software system 104 provides avariety of functions to the operation of the overall system and theproduction method, as augmented by novel custom software 140, 112, and130 that produces machine readable scripts to dynamically propagate datathroughout the production system. Initially, the CAD software 104 takesthe electronic schematic 102 and produces a mechanical drawing 106suitable for the prototype harness build 108. This prototype harnessthen goes through harness verification 110 with a resultant output thatmay modify, by way of CAD software 104 and automated production scriptgeneration process 140, the production harness instructions. This occursgenerally at the creation of harness script 112 and C&C center cut list118, both of which basic script generation 140 derives from CAD software104.

In addition to the feedback loop provided by the prototype manufacturingprocess, CAD software 104 integrates the data associated with theelectronic schematic 102 with the automated quality control and standardcatalog information functionality 114 (again, software driven). Thiscentralized quality control software component receives data fromstandard catalog 116, which in the preferred embodiment is a database ofstandard catalog information related to all of the various componentsthat end up being assembled into the final manufactured wire harness.These components include wire gauge standards, terminal configurations,connector configurations, and so on. All of this information is providedby way of automated quality control and standard catalog reconciliationprocess 114 which provides the same through CAD software 104 to assistwith the creation of harness script 112. A further confirmatory feedbackloop is provided between harness script 112 and quality control andstandard catalog 114.

CAD software 104, through the mechanisms described above, generates C&Ccenter cut list 118 which directs circuit production software 120 tocarry out the circuit manufacture 122. Circuit manufacture is, asdiscussed above with regard to the prior figures, the manner ofassembling the building block components of the wire harness, namely thecircuits comprising lengths of wire with associated wire terminals. Thiscircuit manufacture 122 is carried out with elements from componentstock 128 which has been established by way of a bill of materials 124generated by sourcing and quotes 126, all of which derive from theautomated quality control and standard catalog reconciliation softwaresystem 114.

In addition to generating the C&C center instructions as describedabove, CAD software 104 generates data files that include descriptionsof individual circuits and the harness, but CAD software 104 does notsinglehandedly create harness script 112 as it is used in the presentinvention. Rather, automated production script generation process 140receives data files from CAD software 104 and uses novel custom softwareto generate harness script 112. Harness script 112 contains circuitmechanical descriptions, circuit electrical descriptions, and wireharness manufacturing commands that are sent to assembly system 134, andare quality checked and reconciled with standard catalog 116 byautomated quality control and standard catalog reconciliation process114. In a preferred embodiment, harness script 112 is provided toassembly system 134 in machine-readable format and automatically directsthe functional assembly of the wire harness at assembly system 134.

After automated quality control and standard catalog reconciliationprocess 114 processes harness script 112 and develops the requisiteinformation for tooling script 132, tooling script automated generation130 occurs so as to create tooling script 132. Tooling script 132includes a graphical driver script for assembly system 134. In someembodiments, under the direction of tooling script 132, assembly system134's projectors 512 a and 512 b (shown in FIGS. 13B and 14) projecttext and graphics on layout boards and modules that direct the assemblyperson as to which connector blocks and turn posts to install, where toplace them, and how to orient them. Tooling script 132 also directsassembly system 134 to display text and graphics, with accompanyingaural information, as well as LED light points for connector blocks toindicate the proper insertion points. Further, tooling script 132includes a series of automatically generated test vectors to verifyproper configuration and operation of module configuration.

Tooling script 132, in conjunction with harness script 112, a furthersource of component stock 128, and through the resultant circuitcomponents manufactured 122, all come together in assembly system 134 tocreate wire harnesses 136. As with the prototype build system, there isa feedback loop provided from the wire harnesses 136 through harnessverification process 138 back to a manner of modifying tooling script132 to again facilitate the most efficient operation of assembly system134.

Reference is made to FIGS. 12A-12C which collectively provide acontinuous flowchart of the production process steps for circuitmanufacturing, circuit indexing and storage, and guided wire harnessassembly. FIG. 12A provides the initiation of the production process atStep 150 where programming directed to wire harness individual preparedwire requirements (wire gauge AWG, terminal types, etc.) is carried out.The system then proceeds at Step 152 to supply wire reels and terminalcartridges (bandolier rolls) to cutting, stripping, and crimpingmachines. At Step 154 the system then proceeds to load programming intothe cutting, stripping, and crimping machines, followed by Step 156wherein the system generates a batch of individual prepared wires(circuits) with terminal ends. The necessary automated programming isloaded at Step 158 into the automated indexing storage cart as describedabove. The appropriate programming is loaded at Step 160 into wireharness assembly table and projection assembly guide as described above.Step 162 involves the sorting, indexing, and delivery of preparedcircuits (as each is prepared) into the automated indexed storage cartby way of the pneumatic tube interface system.

FIG. 12B continues the process wherein Step 164 involves loading theprogramming into wire harness assembly table and projection assemblyguide. This is followed at Step 166 where the projection assembly guidesoperate to prompt for the selection and placement of connector jigs andcable turn posts on the assembly table module. At Step 168 the accuracyof the placement of the jigs and turn posts with electrical and lightposition verification is confirmed. The process then proceeds at Step170 to move programmed indexed storage cart to the assembly areaadjacent the wire harness assembly table. The system then connects theindexed storage cart to the assembly table for data communication andmovement of the circuits at Step 172. The system then, at Step 174,delivers individual prepared wires (circuits) to the assembly table fromthe automated indexed storage cart with the pneumatic tube deliveryinterface system.

In the wire harness assembly step shown in FIG. 12C, Step 176 comprisesthe process of running a projection assembly guide to prompt for theplacement of individual delivered prepared wires (circuits) onto wireharness assembly table and into the appropriate connectors positioned onthe connector jigs. This is followed at Step 178 by confirming theaccuracy of the placement of the individual delivered prepared circuitsby way of electrical testing and light illumination indicators. Theprocess is repeated at Step 180 wherein additional prepared wires fromthe automated indexed storage cart, by way of pneumatic tube deliverysystem interface, are delivered to the assembly personnel for placementin association with the assembly table. At Step 182 the system confirmsthe complete placement of all prepared wires (circuits) onto the wireharness assembly along with the associated real time electrical testingand light illumination indicators. The system then, at Step 184, runsthe projection assembly guide to prompt for the placement of cable tiesand bindings on the completed wire harness assembly. Finally, theassembly personnel, at Step 186, remove the completed wire harnessassembly from the assembly table and package it for delivery, havingalready been tested and verified in the manufacturing process.

Reference is made first to FIGS. 13A & 13B for an overview of thevarious sub-systems that collectively are engaged in the overall processfor the production of wire harnesses according to the present invention.FIG. 13A is a partial schematic view of the circuit manufacturingsub-system (C&C centers) of the present invention involving themanufacture of the individual wire/terminal circuits that collectivelygo together to make up a wire harness. In general, reference herein to acircuit refers to the manufactured combination of a length or lengths ofwire provide with (where applicable) terminal ends, that arecollectively gathered into and make up the components within a wireharness. The terminal ends are variable in configuration and may simplyinvolve a wire end stripped and tinned (with solder) for purposes oflater attachment to a terminal block or circuit board. In mostinstances, however, a circuit comprises a length of wire that terminatesat each end with a crimp-on metal terminal, typically of a pin or spadetype. The crimp-on terminals may be either male or female. These metalterminals are most frequently designed to be collectively integratedinto what will herein generally be referred to as a connector, whichforms the end of a bundle of wires within a wire harness.

FIG. 13A shows the circuit manufacturing sub-system 10 as incorporatingautomated C&C center 12 as well as manual C&C center 26. Each of theseC&C centers are in turn associated with indexed circuit storage system(cart/magazine/buffer) 36. These basic sub-systems collectively serve tomanufacture the circuit elements 20 utilized in the production of thewire harness. Automated C&C center 12 may be one of a number ofdifferent commercially available automated crimping machines thatinclude an array of wire supply reels (auto feed) 14 and an associatedarray of wire terminal supply cartridges (rolled bands) 16. AutomatedC&C center 12 will typically have at least one means for programming thedevice. The device may be programmed by operator commands entered intoC&C center programming terminal 18. In another embodiment, automated C&Ccenter 12 may be programmed from a remote data input terminal device. Inyet another embodiment, automated C&C center 12 may be programmed byimporting files from CAD software 104.

Automated C&C center 12 produces a completed wire/terminal circuit 20 ofa length, gauge, and terminal type, as specified by the programmingprovided to automated C&C center 12. Such programming is versatile andcan direct automated C&C center 12 to produce a large number of a singletype of circuit 20 or a long list of entirely distinct circuits thattogether might be eventually bundled to form a wire harness. In thepresent invention, a very efficient operation of automated C&C center 12would be to produce a long list of individual circuits required toconstruct one particular type of wire harness. The C&C center mayproduce a number of circuit sets that are indexed and stored (asdescribed in more detail below) and then later utilized to produce anumber of the same type of wire harness.

Functioning in parallel with automated C&C center 12 is manual C&Ccenter 26. A manual C&C center 26 may be required where one or morecustom circuits 32 might be anticipated in the manufacture andconstruction of a given wire harness. This may result from specializedterminal ends or from a non-typical wire gauge or type. In suchinstances, an individual circuit 32 may be manufactured at manual C&Ccenter 26 which, like automated C&C center 12, includes an array of wiresupply reels 28 and an array of wire terminals supply containers(typically bulk containers) 30. Manual mechanisms for feeding wire andhand selecting terminals to be crimped onto the wire are as known in theart for such manual C&C center configurations.

Automated C&C center 12 and manual C&C center 26 each provide acompleted wire/terminal circuit 20 or 32 which is delivered into anindexed circuit storage system (cart/magazine/buffer) 36 by way of anassociated pneumatic conduit 22 or 34 and a circuit indexing sub-system24. Indexed circuit storage system 36 includes a mobile cart configuredwith a large array 38 of linear tubes 39, each of which may hold one ormore completed wire/terminal circuits. This array 38 of storage tubes 39operates in conjunction with circuit indexing sub-system 24 such thatevery tube 39 within the array 38 of the cart/magazine/buffer 36 isidentified and indexed to contain a known type of circuit element 20 or32. In this manner, indexed circuit storage system 36 may be programmedand loaded with a full circuit element set appropriate for themanufacture of a particular type of wire harness. Wire harnesses may ofcourse come in a variety of configurations having less than ten circuitelements to hundreds of circuit elements. Indexed circuit storage system36 is designed to accommodate simple or complex wire harness circuitsets.

The combination of circuit indexing sub-system 24 and pneumatic conduits22 and 34 serve to deliver completed wire/terminal circuits 20 and 32from the respective C&C centers into a properly indexed storage tubewithin indexed circuit storage system 36. As described in more detailbelow, circuit indexing sub-system 24 is in one embodiment a mechanismfor moving one end of pneumatic conduit 22 and/or 34 to a positionadjacent the storage cart input port array 38 on indexed circuit storagesystem 36. As mentioned above, the entire indexing system may beprogrammed and may in the preferred embodiment be controlled by way ofcomputer system 40. In this manner, each completed wire/terminal circuitfrom the respective C&C center may be directed into a known and indexedstorage tube 39 where it may be held until such time as themanufacturing of that particular wire harness assembly is carried out.The basic structure of the circuit indexing sub-system 24 is an X-Ycoordinate variable position frame and track system that allows for thedirected movement of the end of the pneumatic delivery tube into contactwith the appropriate indexed storage tube.

In one embodiment of the present invention, each of the storage tubes 39associated with indexed circuit storage system 36 may be designed toretain a single circuit element 20 for later delivering during theassembly of the wire harness. Alternate embodiments of the presentinvention anticipate the utilization of storage tubes 39 capable ofretaining a number of like circuit elements for later use and deliveringsuch circuit elements one at a time in a repetitive manner. Therefore,the index circuit storage system (cart/magazine/buffer) 36 may beconfigured to receive, store and deliver a full circuit element setappropriate for the manufacture of a single wire harness or, in analternate embodiment, the same cart may be configured to receive, store,and deliver ten or more sets of circuit elements by repeatedly drawingout a full set for the manufacture of a wire harness followed by secondand subsequent full sets all from the same storage vehicle.

Reference is now made to FIG. 13B. The features with the same numbers inFIGS. 8B and 13B are identical. Therefore, the textual descriptions thatare the same for FIG. 13B as for FIG. 8B are not repeated here. In theview shown in FIG. 13B, indexed circuit storage cart 36 is moved to aposition adjacent the wire harness assembly sub-system 50. Indexedcircuit storage system 36 may include, or may be controlled by, acomputer system 40 that facilitates the automation of the process ofindexing, storing, and delivering the circuit elements. Althoughcomputer system 40 is shown on top of storage system 36, in a preferredembodiment computer system 40 is a computer server system that storesinformation about storage system 36's contents but is not physicallyattached to storage system 36. Also shown in FIG. 13B is storage cartoutput port array 42 similar in structure to the storage cart input portarray 38 shown in FIG. 13A. In one embodiment of the present invention,storage cart output port array 42 may comprise the same array of portsas storage cart input port array 38 and cart 36 is simply turned aroundfor receipt or delivery of the circuit elements. Alternately, thesestorage cart port arrays may comprise opposite ends of the mobileindexed circuit storage systems (cart/magazine) 36.

As with the input of circuit elements into indexed storage circuitsystem 36, the output or delivery of the circuits is carried out, in oneembodiment, by way of circuit indexing sub-system 44 which effectivelyreverses the indexing process and selectively withdraws the appropriatecircuit element from the storage cart to be delivered to the wireharness assembly sub-system 50. This delivery is again carried out byway of pneumatic conduit 46 which withdraws a circuit element fromstorage system 36 and delivers it to wire harness assembly sub-system 50for use in conjunction with the assembly process.

While assembly personnel manually receive circuit elements from thecircuit indexing sub-system 44 by way of the pneumatic conduit 46 asdescribed above, or from circuit indexing sub-system 85 and conveyorbelts 202 and 204 as described above, the process of placing the circuitelement onto the assembly table and making the appropriate connectionsis automatically guided and confirmed by the systems and methods of thepresent invention.

Reference is now made to FIG. 13C for a more detailed description of twoof the more critical components within the system and method of thepresent invention. FIG. 13C is a detailed side plan view of oneembodiment of a circuit indexing sub-system 44 utilized to delivercompleted circuit elements into and out from the mobile storage system(cart/magazine/buffer) 36 of the present invention. It is understoodthat, as discussed above, such an indexing sub-system would preferablybe positioned in conjunction with both the circuit manufacturesub-system 12, 26 (the C&C centers) and the harness assembly sub-system50 (the assembly table) and would provide the manner of directingcompleted circuit elements into the mobile indexing storage cart as wellas providing delivery of the same from the mobile cart to the harnessassembly table. Those skilled in the art will recognize that the systemmay preferably include two circuit indexing sub-systems, one fordelivery of the manufactured circuit elements into the storage cart andone for delivery of the indexed circuit elements from the storage cartto the assembly table. Alternately, the storage cart might retain asingle array of ports that serve as both the input and output ports forreception and delivery of the various circuit elements stored within themobile cart. In other words, the circuit indexing sub-system 44 shown inFIG. 13C could also serve as the circuit indexing sub-system 24described above for receiving manufactured circuit elements into thecart. It would be a simple matter of connecting and disconnecting thepneumatic hoses associated with each of the stations discussed above andappropriately programming the X-Y indexing and sorting system to eitherdirect (pneumatically) a just completed circuit element into the storagecart or to withdraw a previously indexed circuit element from the cart.

In one embodiment, circuit indexing sub-system 44 is connected topneumatic conduit 46 by way of conduit indexing shuttle ring bracket 81.Circuit indexing sub-system 44 is generally comprised of indexing systemX-Y frame 70 as well as X-Y frame controller bracket 72. Positioned oncontroller bracket 72 are X-Y position DC stepping motors 74. Each setof DC stepping motors 74 is connected to and controlled by at least oneX-Y frame microcontroller 76. DC stepping motors 74 are connected toconduit indexing shuttle ring bracket 81 by way of X-Y positioningtension cables 72 a-78 d. These cables extend from cable drive/take-upreels 84, each positioned on one of X-Y position DC stepping motors 74and each terminating on conduit indexing shuttle ring bracket 81 afterpassing over cable corner pulleys 82. In an alternative embodiment,shuttle ring bracket 81 may be positioned using electric screw drivesrather than an arrangement of pulleys as described herein.

The microcontrollers 76 of the present invention therefore direct theappropriate signals to DC stepping motors 74 which turn cabledrive/take-up reels 84 and by tension provided in X-Y position tensioncables 72 a-78 d position and hold bracket 81 and its associatedpneumatic conduit end 46 over any X-Y position within the X-Y frame 70.It is understood that the array of input ports to the storage cabinetare positioned behind or adjacent to the circuit indexing sub-system 44and are thereby accessible at any particular position that conduitindexing shuttle ring bracket 81 is placed. Depending therefore uponwhich storage tube within the storage cabinet a particular completedcircuit element is intended to be stored, the DC stepping motors 74direct the movement of conduit indexing shuttle ring bracket 81 (andtherefore of the pneumatic conduit 46) to a particular location on anX-Y plane defined by the ends of the various input ports associated withthe storage cabinet (not shown). Maintaining tension on each of the X-Yposition tension cables 72 a-78 d allows for any location within the X-Yframe 70 to be moved to and maintained.

Once an X-Y position has been established, the system may activate thepneumatic components associated with the pneumatic conduit and directthe circuit element contained within the pneumatic conduit out from theconduit through the conduit indexing shuttle ring bracket 81 and intothe appropriate input port on the portable storage cart. Those skilledin the art will recognize various mechanisms for directing air flowthrough the pneumatic components of the system as described above. Thesepneumatic components are configured to direct a flow of air through theappropriate tubing components, both for receiving circuit elements intoinlet tubing components (such as by directing a negative pressure onsuch components) and/or to direct a flow of air out from a delivery tubecomponent (such as by providing a positive pressure on such a deliverycomponent). It is anticipated that the air flow movement may be directedfrom components within the storage cart itself creating the negativepressure necessary to draw a properly positioned circuit element intothe storage cart by way of the indexed pneumatic tubing, and likewise todeliver a positive pressure flow of air from the storage cart (by way ofthe appropriate indexed storage tube) to the delivery pneumatic tubethat has been properly positioned to carry the circuit element from thecart to the wire harness assembly table. Various other pneumaticcontrols, seals, valves, and control elements appropriate forimplementing these two basic functions within the pneumatic systemshould be apparent to those skilled in the art.

Reference is now made to FIG. 14 for a description of an improvement andalternate embodiment of the second half of the wire harness productionprocess. The sub-systems described in FIGS. 8A & 8B and other figuresare generally the same and perform the same functions in the improvementdescribed in FIG. 14. However, the invention in FIG. 14 includes certainfeatures that greatly improve upon the earlier invention. The inventionin FIG. 14 includes two conveyor belts 202 arranged so that one isparallel above the other. The distance between the two conveyor belts202 is adjusted to the optimum distance so that each conveyor belt 202comes in contact with the appropriate circuit element from the storagecart to be delivered to the wire harness assembly sub-system 50. Theadvantage of the two conveyor belts 202 arranged in this manner isefficient and consistent delivery of the circuit element 20 from thestorage cart 36 to the wire harness assembly sub-system 50.

The next improvement of the invention depicted in FIG. 14 is theaddition of the double buffer assembly 300. The double buffer assembly300 comprises the circuit element sensor 301, the cover assembly 302,the circuit element buffer tray 303, circuit element buffer 304, and theair knife 305. The circuit element sensor 301 senses the presence orabsence of a circuit element in the circuit element buffer tray 303. Thecircuit element sensor 301 may be any sensor whether optical orotherwise that can detect the presence of absence of a circuit elementin the circuit element buffer tray 303. The circuit element sensor 301transmits the presence or absence of a circuit element in the circuitelement buffer tray 303 to a computer system 40. Upon sensing theabsence of a circuit element in the circuit element buffer tray 303 thecomputer system 40 automatically directs the air knife 305 to depositthe buffered circuit element into the circuit element buffer tray 303and for the delivery of the next circuit element to the circuit elementbuffer 304. The air knife 305 may be any device appropriate to quicklymove the circuit element from the circuit element buffer 304 to thecircuit element buffer tray 303. In the present embodiment this consistsof an air knife as is known in the art. The circuit element buffer 304is protected by the cover assembly 302, which prevents the assemblypersonnel from taking the wrong circuit assembly.

The double buffer assembly 300 allows the assembly personnel to nearlyalways have the next circuit element waiting for assembly in the circuitelement buffer tray 303. The double buffer assembly 300 greatly speedsup the assembly process as the assembly personnel no longer have to waitfor the delivery of the next circuit element from the indexed circuitstorage cart 36, but rather only has to wait for the nearlyinstantaneous delivery of the next circuit element into the circuitelement buffer tray 303.

The figures and descriptions in this application depict specificexamples to teach those skilled in the art how to make and use the bestmode of the invention. These examples are not given to limit the scopeof the invention, but rather to teach inventive principles. To conciselyteach inventive principles, some conventional aspects of the inventionhave been simplified or omitted. Those skilled in the art willappreciate many of the configurations, combinations, subcombinations,and variations on these examples that fall within the scope of theinvention. For example, certain features of the invention described inseparate embodiments can also be implemented in combination in a singleembodiment. Conversely, various features that are described in thecontext of a single embodiment can also be implemented in multipleembodiments—separately or in any suitable subcombination. The inventionis not limited to the specific illustrative examples described herein,but by all embodiments and methods within the scope and spirit of theinvention as in the current, amended, or added claims and theirequivalents. In any case, all substantially equivalent systems,articles, and methods should be considered within the scope of theinvention.

We claim:
 1. A computer-aided wire harness assembly system usingaugmented reality, comprising: a) a wire harness assembly tablecomprising at least two assembly table modules, each of the at least twoassembly table modules being configured to receive one or more circuitelements and other wire harness assembly components; b) an augmentedreality (AR) device being configured and adapted to present an augmentedreality (AR) display, the AR display being adapted to superimpose, on anactual view of the assembly table and the at least two assembly tablemodules, a virtual representation of a proper placement location for theone or more circuit elements and other wire harness assembly components,wherein the superimposition of the virtual representation of the properplacement location for the one or more circuit elements and other wireharness assembly components on the AR display indicates to a wireharness assembler appropriate connections of the one or more circuitelements with one or more of the other wire harness assembly components;and c) a plurality of jigs, wherein each jig in the plurality of jigs isan interface between one of the wire harness assembly components and oneof the at least two assembly table modules, and wherein each jig in theplurality of jig comprises: 1) an enclosure; 2) a single board computerthat interfaces with one of the at least two assembly table modules; 3)a cable configured to connect the single board computer to one of the atleast two assembly table modules; and 4) a pushbutton switch mounted onthe enclosure, the pushbutton switch being adapted and configured toallow the wire harness assembler to respond to prompts.
 2. Thecomputer-aided wire harness assembly system of claim 1, wherein the ARdevice is adapted to present a superimposed virtual representation oftext-based instructions for proper placement of the wire harnessassembly components on at least one assembly table module of the atleast two assembly table modules.
 3. The computer-aided wire harnessassembly system of claim 2, wherein the virtual representation oftext-based instruction is superimposed on the actual view of the atleast one assembly table module in proximity to a location thatrepresents correct placement of a particular circuit element or otherwire harness assembly component.
 4. The computer-aided wire harnessassembly system of claim 1, wherein the AR device comprises augmentedreality glasses.
 5. The computer-aided wire harness assembly system ofclaim 1, wherein each of the at least two assembly table modules areprogrammable, wherein at least one programmable aspect included each ofthe at least two assembly table modules being adapted to verify eachconnection made thereon, and the at least two assembly table modulesbeing further adapted to electrically test each circuit element placedthereon.
 6. The computer-aided wire harness assembly system of claim 5,wherein after verification and testing, the AR device is adapted tosuperimpose a virtual color-coded indicator on the view of theprogrammable modules, wherein the color-coded indicator signifies eithera successful or an unsuccessful circuit element placement or connection.7. The computer-aided wire harness assembly system of claim 6, whereinthe color-coded indicator is virtually displayed in proximity to thesuccessful or unsuccessful circuit element placement or connection.
 8. Acomputer-aided wire harness assembly system using augmented reality,comprising: a) a presentation system, comprising: 1) a circuit elementbuffer surface having a length that is long enough to receive apredetermined length of a circuit element, wherein the circuit elementbuffer surface is positioned to receive the circuit element and totemporarily support the circuit element; 2) a circuit element trayhaving a length long enough to receive the predetermined length of thecircuit element, the circuit element tray defining a space that isaccessible to an assembler; 3) a circuit element sensor for detectingthe presence or absence of the circuit element in the accessible spaceof the circuit element tray; and 4) an air knife for laterally movingthe received circuit element from the circuit element buffer surface tothe accessible space of the circuit element tray; b) an assembly tablecomprising two assembly table modules, the assembly table modules beingconfigured to receive one or more circuit elements and other wireharness assembly components; c) a wearable augmented reality (AR) devicebeing configured and adapted to present an augmented reality (AR)display, the AR display being adapted to superimposed, on an actual viewof the assembly table and the two assembly table modules, a virtualrepresentation of a proper placement location for the one or morecircuit elements and other wire harness assembly components onto one ofthe two assembly table modules, wherein the superimposition of thevirtual representation of the proper placement location of the one ormore wire harness assembly components on the AR display indicates to theassembler appropriate connections of the one or more circuit elementswith one or more of the other wire harness assembly components; and d) aplurality of jigs, wherein each jig in the plurality of jigs is aninterface between one of the wire harness assembly components and one ofthe at least two assembly table modules, and wherein each jig in theplurality of jig comprises: 1) an enclosure; 2) a single board computerthat interfaces with one of the at least two assembly table modules; 3)a cable configured to connect the single board computer to one of the atleast two assembly table modules; and 4) a pushbutton switch mounted onthe enclosure, the pushbutton switch being adapted and configured toallow the wire harness assembler to respond to prompts.
 9. Thecomputer-aided wire harness assembly system of claim 8, wherein thevirtual representation of the proper placement location for the one ormore circuit elements and other wire harness assembly componentsincludes text-based instructions.
 10. The computer-aided wire harnessassembly system of claim 9, wherein the virtual representation oftext-based instructions is superimposed on the actual view of at leastone of the two assembly table modules in proximity to a location thatrepresents correct placement of a particular circuit element or otherwire harness assembly component.
 11. The computer-aided wire harnessassembly system of claim 8, wherein the AR device comprises augmentedreality glasses.
 12. The computer-aided wire harness assembly system ofclaim 8, wherein each of the two assembly table modules areprogrammable, wherein at least one programmable aspect includes each ofthe two assembly table modules being adapted to verify each connectionmade thereon, and the two assembly table modules being further adaptedto electrically test each circuit element placed thereon.
 13. Thecomputer-aided wire harness assembly system of claim 12, wherein afterverification and testing, the AR device is adapted to superimpose avirtual color-coded indicator on the view of the two assembly tablemodules, wherein the color-coded indicator signifies either a successfulor an unsuccessful circuit element placement or connection.
 14. Thecomputer-aided wire harness assembly system of claim 13, wherein thecolor-coded indicator is virtually displayed in proximity to thesuccessful or unsuccessful circuit element placement or connection.